Tunnel lining and method of applying

ABSTRACT

A lining for a cylindrical tunnel is constructed by applying to the tunnel wall a multiplicity of panels of reinforced concrete which are substantially longer than they are wide. The panels comprise peripheral segments with straight side edges and helical end edges and are individually applied and secured directly to the tunnel wall with anchor bolts, in a helical pattern. The circumferential extent of each panel is preferably in the range of 50* to 70*. Length and helix angle are so chosen that the advance for one full turn is equal to the length of a panel. The boring machine bores in increments of predetermined length and grippers are then moved forward and re-set. When the advance of each panel is about equal to one boring advance, one panel may be put in place during each boring cycle. The longitudinal edges of the panels are formed with grout flow channels and inlet and outlet ports communicate with the channels to supply grout to the cavity between the lining and the tunnel wall to form a permanent lining.

United States Patent 1 Ruemmele 1 TUNNEL LINING AND METHOD OF APPLYING Werner A. Ruemmele, 950 E. 1217 N., Bountiful, Utah 84101 [22] Filed: Aug. 8, 1972 [21] Appl. No.: 278,811

[76] Inventor:

521 ms. Cl. 61/42, 61/45 R [51] Int. Cl E21d 11/00 [58] Field of Search 61/84, 85,- 45 R, 42

[56] References Cited UNITED STATES PATENTS 770,894 9/1904 Dutton 61/45 R 935,376 9/1909 -Lennon 61/45 R 1,876,205 9/1932 Crom 61/45 R X 1,982,308 11/1934 Kahn et a1 61/45 R 2,111,405 3/1938 Parker 61/84 2,128,172 8/1938 Warner et a1... 61/84 3,411,826 11/1968 Wallers et a1... 299/31 3,613,384 10/1971 Jacobs 61/42 FOREIGN PATENTS OR APPLICATIONS 1,198,999 12/1959 France 61/45 R 1,019,624 11/1957 Germany 61/45 R 1,939,368 6/1970 Germany 6l/45 R Primary Examinerl)ennis L. Taylor I Attorney, Agent, or Firm Sheridan, Ross & Fields [57] ABSTRACT A lining for a cylindrical tunnel is constructed by applying to the tunnel wall a multiplicity of panels of reinforced concrete which are substantially longer than they are wide. The panels comprise peripheral seg-,

ments, with straight side edges and helical end edges and are individually applied and secured directly to the tunnel wall with anchor bolts, in a helical pattern.

The circumferential extent of each panel is preferably in the range of 50 to 70. Length and helix angle are so chosen that the advance for one full turn is equal to the length of a panel. The boring machine bores in increments of predetermined length and grippers are then moved forward and re-set. When the advance of each panel is about equal to one boring advance, one

panel may be put in place during each boring cycle. The longitudinal edges of the panels are formed with grout flow channels and inlet and outlet ports communicate with the channels to supply grout to the cavity between the lining and the tunnel wall to form a permanent lining;

3 Claims, 8 Drawing Figures PATENTEDHA-YZB m4 3.8 1 2,679

SHEET 3 BF 3 BACKGROUND OF THE INVENTION This inventionlies in the fieldof linings for tunnel walls and is directed-to superior lining components and methods of applying them which are particularly useful in sedimentary rock" formations. It is further directed to a system of tunnel construction in which the lining operation proceeds directly behind the boring operation so that the final permanent lining is installed immediately, saving the complication and cost of installing and removing temporaryv support.

The construction of circular tunnels has followed several rather. consistent patterns for many years past. In soft, wet ground for sewers and subways, one practice has been to drive a cylindrical shield forward by applying great force. A liner is applied close behind the shield usually consisting of steel plate made in cylindrical segments and bolted together as they are put in position. After the tunnel is finished, it is then necessary to build a concrete lining in place, requiring forms and pumped concrete. The concrete liningprevents seepage into or out of the tunnel and provides structural strength to take the load when'the steel liner plates deteriorate. Precast concrete liner plates of small size have also beenused.

Another practice for sewers and aqueducts constructed in sedimentaryrockformations has been the use of machines'commonly'referred to as moles for excavation. These machines have a heavy base section and an extensible and retractable cutter head which is pushed against the tunnel face with great pressure. The cutter head is provided on its front face with many sharp edged rollers and, ash rotates, the extremely high unit pressure of the'rollers'fractures the rocky material and breaks it away. After boring a few feet, the cutter head is fully extended and the base section must be moved forward and-again fixedly positioned, so that the boring step canbe repeatedLThese machines produce'a substantially straight cylindrical hole but wear on the cutters and the magnitude of rock loads result in a variation of-two or three inches of the diameter. It is customary to follow up the boring machine with temporary support means including various archedroof plates and anchor belts, or curved beams, to prevent collapse ofthe tunnel. One example is disclosed in US. Pat. No. 779.894 to Chauncey N. Dutton.'By the time the tunnel is completely bored, which may be as much as a year or more, the'exposed rock may be deteriorating. In any event, the tunnel must be cleaned out, and a complete concrete lining poured in place at great expense.

SUMMARY OF THE INVENTION The present invention overcomes the -difficulties mentioned above and provides -a construction and method of achieving it :which maybe considered optimum because the'final liningisperm'anently in place almost immediately after the boring is finished, much less material is used, the cost is greatly reduced, and the final construction:issuperior to that of the prior art.

Generally stated,'the lining is made up of a plurality of identical panels, each of which is secured to-the tunnel wall as well as -to adjacent panels. Each panel is made of reinforced concrete "which is prestressed for added strength,-andcomprises a segment of a cylinder,

usually in the range of 50 to 70, with straight parallel axially extending side edges and helically angled end edges, and is substantially longer than it is wide. The

panels are laid up directly against the tunnel wall in a helical pattern with the end edges forming a continuous helical margin so that each panel advances over the previous one by a distance which is a factor of the panel width and the helix angle.

Nominally, about six panels represent one full turn of the helix. However, variations in the tunnel diameter and handling convenience may produce. a turn of slightly more or slightly less than six panels. Since allof the panels are identical in plan form, they will all fit neatly together even though the longitudinal edges of one turn may not be exactly aligned with those of the adjacent turn. Since each panel has an arcuate extent in the range of 50 to 70, they are so wide that they can follow the gradual variation in tunnel diameter with no appreciable facewise misalignment.

As each panel is sequentially put in place it is forced into edgewise pressural engagement with the laterally and longitudinally preceding panels and locked in position with an anchor bolt to produce a practically unitary structure having highresistance to external forces. Since the panels are preformed and rigid,'they may be secured in place as close to the excavation face asinterfering structures of the boring machine will allow. Hence, temporary support means are not' necessary except when soft spots are encountered, and then only for a very short period of time.

The operation of the boring machine causes vibration, making itdifficult-to set the panels in place. However, the machine's bore about three and-one half feet in a cycle or increment, after'which the gripper section is moved ahead and setin a new position. During this vibration-free interval, one or more panels that have been manipulated near their destination during the'boring cycle may be readily set in place. The'helical angle .of the end edges is selected so. that the advance of one panel over the preceding one is substantially equal to the advance of the machine during one boring increment. Consequently, the total lining advances at the same rate as the total boring, and the lined tunnel is completed only hours after completion of the boring.

The smooth inner walls of the panels and their. good alignment with each other produce an extremely BRIEF DESCRIPTION OF THE DRAWINGS Various otheradvantages and features of novelty -will become apparent as the description proceeds'in conjunction with the accompanying drawings, in which:

' FIG. 1 is a longitudinal section through a partially completed tunnel showing a typical boring machinej 'FIG. 1A is a longitudinal section of an adjacent and rearward portion ofthe tunnel of FIG. 1 showing an apparatus for unloading panels from muck cars and a portion of the novel tunnel'lining set in place;

FIG. 2 is a vertical section taken along line 2-2 of FIG. 1A showing a supply of panels on a muck car;

FIG. 3 is a diagrammatic view in perspective of a single panel;

FIG. 4 is a diagrammatic sectional view through a portion of the lining, on an enlarged scale showing how two adjacent panels are interconnected;

FIG. 5 is a fragmentary, diagrammatic view in section through a completed portion of a lined tunnel; FIG. 6 is a fragmentary enlarged plan view of a connection between adjacent panels; and

FIG. 7 is a diagrammatic sectional view taken along line 7- 7 of FIG. 3, on a greatlyenlarged scale.

DESCRIPTION OF PREFERRED EMBODIMENTS A boring and lining operation being carried out in accordance with the principles of the present invention is illustrated schematically in highly idealized form in FIG. I, where the tunnel section 10 previously bored in the subterranean zone 12 has a head or face 14 in a generally diametral plane representing the present extent of the excavationeThe boring machine 16 has a heavy base section 18 supported on extensible feet or support shoes 20 which are adapted to advance the base section in increments and maintain it in the'right attitude to bore in the direction desired. Gripper shoes 22 are mounted to extend radially into contact with the tunnel wall 24 andare driven by hydraulic pumps (not shown) to grip the wall tightly enough to maintain the position of the base section during a boring increment.

The base section includes a cab 26 having anoperator's compartment 28, which includes a console 30 for operating boring machine 16. The boring machine includes a cutter head 32 whichis mounted for axial and rotational movement and is advanced and retracted by hydraulic cylinders, not shown. It is rotated by motors, such as motors 34 and 36 as shown. On the forward face and margin of the cutter head a plurality of rollers 38 are mounted for free rotation. When the cutter head is urged forward, the contact of the rollers with the surface creates extremely high unit pressures which fracture the rock and cause it to fall away in small pieces. Buckets 40 located at the rear of the cutter head pick up the muck and drop it'onto conveyor 42 through their openinner ends as they pass top center. The conveyor'42 carries the muck 43 to the rear of'the cab and drops it into a hopper 44. The muck is discharged from hopper 44 onto a second conveyor 45 which carries the muck along bridge 46 and over a train of muck cars 47 in a gantry 48 to the forwardmost carlnot shown) of the train. As each car is filled the train will be moved forwardly by one car length. During this movement cured in place. Two manipulator rings 57 are mounted conveyor is shut down so that muck is not dropped between cars, and hopper 43 serves as a surge pile since conveyor 42 and boring machine I6 continue operat- In the position shown, the cutter head has advanced and bored' a full increment of predetermined length.

Gripper shoes 22 are now retractedand moved forward to hold the base section 18 in position and the cutter head isrotated and slowly advanced to bore another full increment. This same sequence is repeated until the full tunnel is bored. The second conveyor 45 which is mounted on elongate'truss or bridge 46 is moved forward each time base section l8.is advanced. l

The lining 49 is applied directly to the wall 24 of the tunnel as close behind the boring machine as possible. As seen in FIG. IA, a plurality of panels 50 have been mounted in position in a helical pattern, each being secured to the wall as it is placed in position. With this system,the final permanent lining is completed almost simultaneously with one completion of the boring, and no temporary support means need to be installed or removed except when soft spots are encountered. As will be explained in detail later, the end edges of the panels are formed as portions of'a helix, and the advance of each panel over the previous panel is approximately equal to the advance of the machine in one boring increment.

Various utilities must be supplied to the boring machine and workers in the tunnel. For clarity of illustration, the means for supplying these utilities is omitted in FIGS. 1 and LA, but is shown diagrammatically in FIG. 2. For example, air may be supplied through a fan line 51 adjacent the top of tunnel l0. Conveniently, a high voltage line 52, a main water line 53 and compressed air hoses 54 are located along one side of the tunnel, as shown. The manner in which all of these utility lines are suspended and connected within the tunnel will be readily apparent to one skilled in the art.

As best seen in FIGS. 1A and 2, gantry 48. moves forwardly with the boring machine 16 and bridge 46 is pulled along tracks 55 mounted on cross ties 56. Additional' tracltage and ties are laid along the tunnel floor as required.

Conveniently, each time an empty train of muck cars is brought into the tunnel, the forwardmost car can be loaded with a supplyof panels 50, as shown in FIGS. IA and 2. Although four panels are shown, the exact number will depend on tunnel size. Advantageously, each empty train should bring in enough panels for use during the filling of all of the muck cars on the train. In some installations it maybe desirable to carry the panels on edge.

The size of the tunnel and the type of muck hauling system used in any particular tunnel will dictate what type of device will be used to manipulate the panels from the muck car and to set them in place. Obviously, in very large tunnels, cranes or other standard apparatus can be used, while in smaller tunnels, special handling apparatus may need to be employed.

7 By way of example, one method of installing the lining is diagrammatically illustrated in FIG. 1A, where it will be seen that several panels have already been se around the truss for longitudinal motion and rotation, and each carry a hoist means, such as a hydraulic cylinder 58 for handling the panels.

To install the top panel of the stack, manipulator 7 rings 57 are moved to a position directly above the stack of panels and grippers 59, which may be vacuum or magnetic, are applied to the inner wall of the panel, and it is lifted off the stack. Of course, if magnetic grippers are used, suitableiron or steel plates must be embedded in the panels at appropriate positions so that the panels may be lifted. The manipulator is then moved forward to clear the stack and the muck car and rotated to bring the panel toward its intended permanent place in the tunnel lining, and the cylinders 58 are extended to push thepanel against the rock where it is firmly set in place. An anchor hole is then drilled through an aperture in the panel into the tunnel wall or I All of the panels are installed in a similar manner. It will be obvious that it would be impossible to construct a permanent concrete liner with the use of forms and inplace concrete at this location because of all the components and equipment which must be present in the tunnel.

The various detailed features of a single panel are shown in FIG. 3, where it will be seen that its developed plan form is a parallelogram and that its axial length is substantially greater than its width, preferably more than four times. The panel is actually a segment of a cylinder with its arcuate extent being approximately 50 to 60 so that six or seven panels will complete a cylindrical segment. The side marginal edges 82 extend axially parallel to each othe'rand its end marginal edges 84 comprise portions of a helix and are parallel to each other. The helical angle is preferably about 40 to accomplish a substantial advance per turn of the helix without angling the pointed corners so acutely that they may be readily damaged. In a typical example a panel has a circumferential width of about 4 feet and an axial length of about feet. With a 40 helical angle, the advance per panel is a about 3 feet and the advance for a full turn of the helix is about 20 feet, so that the lining advances a panel length'per turn. The advance of the boring machine is about 3 feet per boring increment, so that one panel may be installed during each interval of adjustment between boring increments.

Since the panels are pre-cast they may be provided with very smooth inner walls which provide several advantages. The efficiency of water flow is markedly affected by the condition of the conduit-wall, and a very smooth-wall, such as provided by the present invention,

will allow as much flow as a rough wall in a conduit 5 percent or more larger in diameter. This difference in size represents a large difference in the cost of construction. The-axialjointsbetween the panels do not hinder flow and the'helical joints do not hinder flow as much as would right angle joints. The great length of the panels further decreases the frequency of such joints. Furthermore, the panels are very accurately matched to eachother, and the helical joints may be made smoother by grinding or buffing.

Each panel is provided with a plurality of elongate axially extending tendons 85 between the inner and outer walls which are cast in place in tension so that they will after loadtransfer maintain the panel continuously in' compression, greatly adding to its load resistance. Panels in the upper quadrants will be securely held in place against the tunnel wall by a single anchor bolt passing through an aperture .86, which is located near the leading edge of the panel, as shown in FIG. 3.

Although the tunnel wall is substantially cylindrical it is still rather rough because it is formed by breaking away the rock. Also the wear on the gauge cutters produces some gradual variation in the nominal diameter.

the tunnel wall in line .with aperture 86 to receive the lnlet ports 90 at the inner wall and outlet ports 92 at the outer wall communicate with the groove, and grout guns may be connected to ports 90'to force grout in and along the grooveand out through ports 92 to fill the relatively small gap between the lining and the rough tunnel wall. The groove serves a dual purpose, for short pieces of pipe 94 will be laid at intervals in the groove and serve as keys'to accurately align each panel with the adjacent one as it is set in place. This keying effect is clearly illustrated in FIG. 4. It will be noted that while the pipe serves as a key its open center allows free flow of groutalong the channel formed by the confronting grooves 88.

A diametral section through a complete lining is shown in FIG. 5, which in this case comprises six panels in a cylindrical segment to show the location of the tendons and various. grout passages. It also shows a lap plate 96 secured by bolts 98 to the corners of laterally adjacent panels to further unitize the construction. The plate fits into cut-away recesses 100 of the panel corners, as may be seen in FIGS. 3 and 6. Additional recesses 102 may be formed in the opposite corners to allow the plate to overlap longitudinally adjacent panels. After assembly is completed, the recesses may be patched with mortar 104 to preserve a smooth inner surface. I v I The detailed construction of the anchor bolt aperture 86 is shown in FIG. 7. A first recess 106, which may be frustoconical, is formed in the inner wall of the panel and a second similar recess 108 of lesser lateral dimensions is formed in the outer wall, meeting the first recess at a mid-point of the thickness to define aperture 86 and a shoulder 110, on which a pressure distribution plate 112 is mounted, the plate having a central aperture 114. A wedge-shaped washer 1.16 is mounted on the shank 118 of bolt 120 immediately under headl22 and may be angularly adjusted to permit the bolt to extend in any selected angular direction.

' When a panel of the upper quadrants is set in place it may be forced tightly edgewise against the adjoining panels and also against the tunnel wall by cylinders on the hydraulic manipulator and an anchor hole drilled in anchor bolt. The hole, and consequently the bolt, may be directed at an angle to the radius passing through the bolt head or at an angle to the diametral plane passing through the bolt head, or both, to allow drilling past the bridge truss.

ceding panels into the best possible fit with the tunnel and each other. Because of the continuing helix, the axial joints of one pass do not have to be in alignment with those of the adjacent pass. Theyfit in any relation, as illustrated in FIG. 1.

Each side edge 82 is formed with a semi-cylindrical recess or groove 88 along a major portion of its length.

It will be apparent that the lining material and method of applying it as disclosed herein provide a novel system for constructing a tunnel withoutneed for installation of a temporary lining, and in which the installation of the pennanent lining proceeds substantially simultaneously with boring of the tunnel.

The invention has been described in detail with reference to a preferred embodiment thereof, but it will be understood that variations and modifications can beeffected within the spirit and scope of the invention.

What is claimed is:

l. A method of constructing a permanently lined tunnel wherein the size of the tunnel is such that the central and major portion thereof is occupied by boring equipment, such as, a drill, conveyor, track, muck cars and utility lines, and the permanent lining is installed as the tunnel is bored, said method comprising: a

boring a continuous substantially cylindrical hole in incremental strokes of a predetermined length with concrete panels in the form of cylindrical segments for securement directly to the tunnel wall in a helical pattern by manipulating the panels in the space between the boring equipment and the tunnel wall immediately behind the mole drill simultaneously with advancement of the mole drill wherein each of the panels is of a length substantially equal to the length of the incremental strokes;

and securing the rigid panels to the wall in edgewise pressural engagement with each other so that the lining is advanced an incremental length substantially the same as the incremental length of the previous boring stroke so that the tunnel is permanently lined immediately behind the drill at the same rate as the drilling is accomplished.

2. A method as claimed in claim 1; wherein an anchor bolt is passed through each panel and anchored in the tunnel wall to secure the panel to the wall;

and the bolt axis is directed at a predetermined angle to urge'the panelinto edgewise pressural engagement with the laterally and longitudinally'precedingpanels of the-lining. v

3. A method of constructing a completed tunnel in which the tunnel is bored and permanently lined simultaneously and wherein thesize of the tunnel issuch that the central and major portion thereof is occupied by boring equipment, such as a drill, conveyor, track,

muck cars and utility lines, said method comprising the steps of:

position and the boring operation repeated in a series of boring increments and adjusted increments;

removing all muck from the boring operation on muck cars traveling along a central portion of the tunnel;

bringing panels in the form of cylindrical segments into the tunnel in empty muck cars to a position immediately behind the mole drill;

removing each panel from a muck car and then manipulating it in an area outside said central zone during a boring increment to a position to be applied to the tunnel wall;

setting each said panel in position during an adjustment increment and thereafter securing it in place,

said panels'being of such size that the placing of each panel advances the permanent tunnel lining a distance substantially'equal to each' advancement of said mole drill so that the tunnel is simultaneouslyand permanently lined as the drilling oper ation proceeds. 

1. A method of constructing a permanently lined tunnel wherein the size of the tunnel is such that the central and major portion thereof is occupied by boring equipment, such as, a drill, conveyor, track, muck cars and utility lines, and the permanent lining is installed as the tunnel is bored, said method comprising: boring a continuous substantially cylindrical hole in incremental strokes of a predetermined length with a mole drill in a subterranean zone substantially of sedimentary rock; sequentially positioning rigid, permanent, reinforced concrete panels in the form of cylindrical segments for securement directly to the tunnel wall in a helical pattern by manipulating the panels in the space between the boring equipment and the tunnel wall immediately behind the mole drill simultaneously with advancement of the mole drill wherein each of the panels is of a length substantially equal to the length of the incremental strokes; and securing the rigid panels to the wall in edgewise pressural engagement with each other so that the lining is advanced an incremental length substantially the same as the incremental length of the previous boring stroke so that the tunnel is permanently lined immediately behind the drill at the same rate as the drilling is accomplished.
 2. A method as claimed in claim 1; wherein an anchor bolt is passed through each panel and anchored in the tunnel wall to secure the panel to the wall; and the bolt axis is directed at a predetermined angle to urge the panel into edgewise pressural engagement with the laterally and longitudinally preceding panels of the lining.
 3. A method of constructing a completed tunnel in which the tunnel is bored and permanently lined simultaneously and wherein the size of the tunnel is such that the central and major portion thereof is occupied by boring equipment, such as a drill, conveyor, track, muck cars and utility lines, said method comprising the steps of: boring a cylindrical tunnel through a sedimentary rock zone with a mole drill having a cutter head and retractable grippers which are held in fixed position against the walls of the tunnel while the cutter head is advanced a predetermined distance, the grippers thereafter being retracted and the drill advanced said predetermined distance to a new fixed position and the boring operation repeated in a series of boring increments and adjusted increments; removing all muck from the boring operation on muck cars traveling along a central portion of the tunnel; bringing panels in the form of cylindrical segments into the tunnel in empty muck cars to a position immediately behind the mole drill; removing each panel from a muck car and then manipulating it in an area outside said central zone during a boring increment to a position to be applied to the tunnel wall; setting each said panel in position during an adjustment increment and thereafter securing it in place, said panels being of such size that the placing of each panel advances the permanent tunnel lining a distance substantially equal to each advancement of said mole drill so that the tunnel is simultaneously and permanently lined as the drilling operation proceeds. 